• Enjoy a unique environment to meet and gain input from all stake holders on industry direction, challenges and solutions.• Shape your strategy on the way solutions should be developed and applied in your facility• Understand how partnering can take you further, faster and with reduced risk• Experience hands on demonstrations of automation equipment and packages.

The invitation was interesting, and challenging. “Future.Now – Developing the Life Sciences Landscape Together” was an arresting title. It was a co-operative event between National Institute for Bioprocessing Research and Training (NIBRT) and Emerson. We were invited to “Boost your knowledge, gain from the experience of others and increase your professional network at NIBRT state of the art facility in Dublin!”

Mike Train, Executive President with Emerson explains their focus under the attentive eye of European President Roel Van Doren.

This correspondent was aware of the NIBRT facility but had very little idea of what it was real function or its relevance to Irish industry. This was an opportunity find out. Further looking through the programme two things became apparent. One was the calibre of personnel speaking from the Emerson organisation and then the application rather than product orientation of the various sessions.

It proved to be a very interesting two days.

Day 1: Working together towards a common future.Presentations from NIBRT, Industrial Development Authority (IDA), GSK, Alexion, Zeton, Novo Nordisk and Emerson Automation Solutions.

Pharma v Biopharma

After a short welcome fro Emerson Europe President, Roel Van Doren, the CEO of NIBRT, Dominic Carolan, outlined the foundation and raison d’etre of the organisation. It is a training and research in the area of bioprocessing. It is located in a new, world class facility in Dublin (IRL). As medical science advances “simple” chemistry, while still essential, is not fully capable of solving all health issues – Pharma versus Biopharma. Bioprocessing is a specific process that uses complete living cells or their components (e.g., bacteria, enzymes, chloroplasts) to obtain desired products.

Thus this facility exists to support the growth and development of all aspects of the biopharmaceutical industry in Ireland. It is purpose built to closely replicate a modern bioprocessing plant with state of the art equipment.

Making Ireland ready – a good news story.Dr Chantelle Keirnan, Scientific Advisor with the Industrial Development Authority (IDA), described the far-seeing intuitive initiative to look at bioprocessing “before it was profitable or popular!” This state body is responsible for the attraction and development of foreign investment in Ireland and had been extraordinarily successful in attracting nine of the top ten pharma companies to set up manufacturing processing plants in Ireland. They considered at the turn of the century that bioprocessing was the way that life science was going and took steps to ensure that Ireland was ready. One of those steps was the provision of Government funding of NIBRT.

Togged out for the tour

Many of the delegates – in excess of one hundred attended some from other countries – donned white coats and took the opportunity to tour the impressive facility during the event. It includes a purpose-built, multi-functional building which replicates the most modern industrial bioprocessing facility. Some idea of this facility may be gleaned from their website here.

This is a good news story. How often are decisions of state organisations regarded, not entirely without justification, with a jaundiced eye? Those that are good are “oft interréd with their bones!” The vision that saw this development in industry and the individuals who having caught the ball ran with it and brought it so successfully to fruition is worthy of equal attention and praise.

The rest of the day was an examination of the industry, processes and looking into the future. Mike Train, Executive President of Emerson spoke on the changes that are influencing industry and his company’s focus. We are facing “an evolution not a revolution” he stated, a point emphasised by other speakers throughout the day. He also stressed the importance for giving permission to change. (See full list of speakers at below.)

Pictures from the event!

We then had a series of speakers from the industry, people who get their hands dirty so to speak in actual processing speaking of their experiences and challenges. Speakers from GSK and Novo Nordisk explored areas like partnership, legacy issues, building on or expanding existing plants, saving energy, wireless. There was some discussion on the cloud and its advantages and just how vulnerable it might be to security breaches.

The discussion on handling all this data and identifying and retrieving those pieces of data which are really useful to the process brought to mind the prophetic words of the American media theorist, Neil Postman years ago, “…a central thesis of computer technology – that the principal difficulty we have in solving problems stems from insufficient data – will go unexamined. Until, years from now, when it will be noticed that the massive collection and speed of light retrieval of data have been of great value to large scale organisations but have solved very little of importance to most people and have created at least as many problems for them as they have solved…” (Neil Postman: “Amusing ourselves to death:” 1985)

Peter Zornio, Chief Technology Officer with Emerson gave their philosophy in meeting the demands of “Life Science Visions.” He lauded the various discussion groups such as the Biopharma Operations Group in helping how to keep up to date with technology and fostering new ideas.

We are on a digitizing journey. Moving from manual and paper to digital recording and control.

Day 2: “New Technology, New Processes, New solutions!”Presentations from BioPharmaChem, GSK, Infinity Automation and Emerson.

The day started with a presentation on modular flexible manufacturing – introducing the PK Controller and a little later in the day there was an exposition on DeltaV Discovery/DeltaV 14 in maintaining data and transferning and easing technology transfer through the life cycle of drug development.

In his second presentation Peter Zornio gave the business case behing IIoT. IoT is usually referring to domestic, building environment and other civil applications. But it is also useful in the industrial environment where it is referred to as IIoT. Initially it was a link up at the instrument and control area but of late it is spreading to the portfolio of sensors. Their emphasis is on “the first mile!” (This is a backward reference to the perennial problem in many, especially rural, areas of “the last mile” – the internet connection directly into the home! – a heart felt sigh from your correspondent!)

The Real Challenges!

Ian Allen of Infinity Automation spoke on challenges to the life science automation world. “Don’t go backward to go forward” he said. We must use things like data integrity, cyber security, Microsoft dependencies and Industrie 4.0 as “gifts to leverage the opportunity and change!” The real challenge is not so much the technology but our use of it. We were coming back to “permission for change!”

We might perhaps use the words of the Bard of Avon, “The fault, dear Brutus, is not in our stars. But in ourselves….” The “gifts” are there. The Technology is there or on the way.

Let’s own these gifts and make them our own.

Pic: Travis Hesketh

The Speakers:

Day 1

Dominic Carolan

CEO – NIBRT

Dominic Carolan was appointed CEO of NIBRT in April 2015. Mr. Carolan previously held senior roles in Mallinckrodt (Dublin), Genzyme (Waterford), also Genzyme (Corporate) where he was Senior Vice President of Manufacturing, and in Sanofi, where he headed their global network of Sterile Injectable Lyophilisation sites. He has successfully lead the startup of two significant Pharma & BioPharma facilities in Ireland and has a proven track record in operations leadership and in attracting and developing the talent required to deliver long term success. A graduate of UCD in Chemical Engineering, Mr. Carolan was Chairman of BioPharmaChemical Ireland from 2008-2010.

Dr Chantelle Kiernan

Scientific Advisor – IDA

Dr. Chantelle Kiernan joined IDA in September of 2009 and is responsible for attracting research related foreign direct investment for Ireland. Chantelle has responsibility for the Multinational research portfolio – spanning Pharmaceutical, Biotechnology, Medical Device, Engineering Food services industries. Chantelle has spent her career equally dispersed between academia and industry. She holds a PhD in Immunology from Trinity College Dublin in the area of immunomodulation and continued her academic career with a Post-Doctoral fellowship in Harvard University, Boston. Chantelle is currently undertaking an MSc in International Business law. She has spent almost fifteen years in industry. In her current role as Scientific Advisor for the IDA, she has been integrally involved in attracting and securing large scale R&D foreign direct investments for Ireland.

Mike Train

Executive President – Emerson Automation Solutions

Michael H. Train leads the Automation Solutions business of Emerson, which posted sales of $10.2 billion in fiscal 2015. Train began his career with Emerson in 1991 as an international planner, then took on additional responsibilities in a number of executive posts that included serving as President of Emerson Japan and Korea, VP of Corporate Planning, President of Emerson Process Management Asia Pacific, and President of Emerson’s Rosemount business. He was most recently President of Global Sales for Emerson Process Management, responsible for sales, service, support, and customer satisfaction for all products and services across five world-area organizations. In that role he was also part of the leadership team that drove strategic initiatives and investments for the entire business group. Train earned a bachelor’s degree in electrical engineering from General Motors Institute and an MBA from the Johnson Graduate School of Management at Cornell University. He currently serves on the management school’s advisory council and was a 2008 Eisenhower Fellowship recipient.

Dave Tudor

Vice President, Head of GMS Strategy – GSK

Dave joined GSK in 1992 at Worthing as a PhD Chemist from Glasgow University. He has over 20 years’ experience with the company carrying out a number of Technical, Compliance and Manufacturing leadership roles. In 1997 he moved to Irvine to take up a lead chemist role before coming Quality Control Manager in 1998. He joined the site leadership team in 2001 to run Technical Development before moving to manufacturing as Actives Production Director in 2005. During this time he completed a Masters degree in Manufacturing Leadership at Cambridge University. In 2007 he moved to GSK House to work on a central network re-structuring project before becoming Site Director at Montrose in October 2008. At Montrose, he led the transformation of the site to manufacture over 12 products for GSK including a major investment programme. In 2011 he was appointed VP Primary Supply Chain with responsibility for global Active Pharmaceutical Ingredients (API) manufacture and supply, a network of GMS sites across the world including facilities in Asia and Europe. In 2017 he was appointed VP Head of GMS Strategy with responsibility for manufacturing strategy, deployment of strategic programmes, performance management and advocacy. He plays an active role with a number of Governments and is currently co-chair of the Life Sciences Scotland Industry Leadership Group. Dave is also a member of UK Chemicals Industry Association Council and Board. Dave is married with 4 children and lives in Troon, Ayrshire. He enjoys all sports, particularly football, is a keen reader of Scottish history and does cooking to relax.

Peter Zornio

Chief Strategic Officer – Emerson Automation Solutions

As Chief Strategic Officer for Emerson Automation Solutions, Peter has responsibility for overall coordination of technology programs, product and portfolio direction, and industry standards across the Automation Solutions group. He has direct responsibility for the product definition and development organizations for control systems and software products. He has been at Emerson for 10 years. Prior to Emerson, he spent over 20 years at Honeywell in a variety of technology and marking roles, most recently as overall product management leader. Peter holds a degree in Chemical Engineering from the University of New Hampshire.

Herman Bottenberg

Marketing Director,, Zeton

PDEng. Ir. Herman Bottenberg is a chemical engineer with 15+ years of industrial experience, along with two years of Post academic work on Plant Design. He worked for 17 years at Zeton B.V. in The Netherlands, with five years of experience in project engineering and project management. The last 12 years he has been active in business development, sales and marketing. Since 2016 Herman is also responsible for the Marketing and Sales group at Zeton B.V. Herman has specialised in transformation of processes from batch to continuous, process intensification and modular processing plants for pharma and chemical industry.

Day 2

Matt Moran

Director – BioPharmaChem Ireland

Matthew Moran is Director of BioPharmaChem Ireland. He graduated in Chemistry at Trinity College Dublin in 1980 and in Chemical Engineering at University College Dublin in 1981; he holds an MBA also from University College Dublin (Smurfit School of Business). He worked for over ten years in the pharmaceutical industry where he held a number of management positions both in active ingredient and dosage form manufacture. He is a member the European Chemical Industry Council (CEFIC). Matthew Moran is a Board member of the Active Pharmaceuticals Ingredients (API) Committee of CEFIC (CEFIC/APIC) and The European Association for Bioindustries (Europabio) BioPharmaChem Ireland represents the interests of the biopharmachem sector in Ireland. CEFIC/APIC represents the European API Industry. Europabio represents the European Biotech Sector.

Ian Allan

Automation Consultant – Infinity Automation

Currently the Managing Director of Infinity Automation, a relatively new company carrying out Automation & MES Consultancy, Strategic Planning and Major Program/Project Health checks, with blue chip Global Life Science companies and Strategic vendors that support that Industry. Formerly Ian was the Global Head of Automation & MES with Novartis, where he was responsible for the Manufacturing Automation Strategy and MES Program within Technical Operations in the Vaccines division. Prior to that he worked for GSK as Global Automation Director responsible for Automation, Process Control and MES across 73 sites worldwide. There he led a team that developed a library of Emerson DeltaV modules to be deployed in multiple Bulk API sites across the world, as well as developing a blueprint for MES integration and Network delivery of Electronic Batch Records. Prior to that he held several roles in GSK within the Engineering and Automation departments. Ian started his career with IBM as a junior engineer when computers were a little bigger than they are today and holds a BSc in Electrical & Control Engineering from Strathclyde University. He is currently facilitating GSK’s Global Automation Steering Team and is leading the Digital Factory Automation workstream for a new Hybrid Manufacturing platform with the first instance being delivered in GSK Singapore Jurong site.

Colin Chapman

Director of Manufacturing IT – GSK

Colin Chapman is a Chemical Engineer with nearly 20 years experience in Life Sciences with GSK. Colin’s career has spanned across process engineering & automation, operations and new product introduction in both commercial manufacturing and clinical supply chains. In his current role as Director of Manufacturing IT Colin has successfully led the introduction of Manufacturing Operations Management across the clinical supply chain driving business process re-engineering and global workflow automation using technologies such as Syncade. GSK’s continuing program focuses on three value drivers, Compliance, Business Intelligence and Productivity.

Klaus started his Emerson career in 2003 in Germany, where he was working as a Technical Manager for Key Accounts before he transferred to Austin, TX to become the DeltaV Hardware Product Marketing Manager. In 2015, he went back to Europe and took over another Global Role, being now the Technical Consultant to some major Strategic Accounts. While in Germany with Emerson, he was responsible for the technical aspects of the DeltaV Systems during the Sales and Implementation Phase, as well utilizing the latest Hardware and Software features while upgrading and expanding Systems on Key Customer sites. Prior to Emerson, Klaus was with the Hoechst AG, he did several Engineering projects with various PLC and DCS and SIS Systems and was as well a RS3 System User.

Danny Vandeput

Director Pervasive Sensing Strategies – Emerson Automation Solutions

The (Industrial) Internet of Things (IIoT) is revolutionizing the way we live but it also provides many new challenges to the industry. This can create confusion, uncertainty – combined with fuzzy statements – and different opinions. My great passion is to bring clarity in the Industrial Internet of Things and what benefits it can bring for you. I help industries to find the right perception of IIoT, how sensors can maximize profit, reduce downtime and bring the ROI into the IoT. Being already 23 years with Emerson I have assisted many types of industries on their way to Top Quartile Performance. This includes amongst other trainings, workshops, audits and implementing solutions.

Adam Bannaghan, technical director of Design Rule, discusses the growing role of PLM in managing quality and compliance.

The advantages of product lifecycle management (PLM) software are widely understood; improved product quality, lower development costs, valuable design data and a significant reduction in waste. However, one benefit that does not get as much attention is PLM’s support of regulatory compliance.

Nobody would dispute the necessity of regulatory compliance, but in the product development realm it certainly isn’t the most interesting topic. Regardless of its lack of glamour, failure to comply with industry regulations can render the more exciting advantages of PLM redundant.

From a product designer’s perspective, compliance through PLM delivers notable strategic advantages. Achieving compliance in the initial design stage can save time and reduce engineering changes in the long run. What is more, this design-for-compliance approach sets the bar for quality product development, creating a unified standard to which the entire workforce can adhere. What is more, the support of a PLM platform significantly simplifies the compliance process, especially for businesses operating in sectors with fast-changing or complicated regulations.

For example, AS/EN 9100, is a series of quality management guidelines for the aerospace sector, which are globally recognised, but set to change later this year. December 2016 is the target date for companies to achieve these new standards – a fast transition for those managing compliance without the help of dedicated software.

Similarly, the defence industry has its own standards to follow. ITAR (International Traffic in Arms Regulations) and EAR (Export Administration Regulations) are notoriously strict exporting standards, delivering both civil and criminal penalties to companies that fail to comply.

“Fines for ITAR violations in recent years have ranged from several hundred thousand to $100 million,” explained Kay Georgi, an import/export compliance attorney and partner at law firm Arent Fox LLP in Washington. “Wilful violations can be penalised by criminal fines, debarment, both of the export and government contracting varieties, and jail time for individuals.”

PLM across sectors
The strict nature of all these regulations is not limited to aerospace and defence however. Electrical, food and beverage, pharmaceutical and consumer goods are also subject to different, but equally stern, compliance rules.

Despite varying requirements across industries, there are a number of PLM options that support compliance on an industry-specific basis. Dassault Systèmes ENOVIA platform, for example, allows businesses to input compliance definition directly into the program. This ensures that, depending on the industry, the product is able to meet the necessary standards. As an intelligent PLM platform, ENOVIA delivers full traceability of the product development process, from conception right through to manufacturing.

For those in charge of managing compliance, access to this data is incredibly valuable, for both auditing and providing evidence to regulatory panels. By acquiring industry-specific modules, businesses can rest assured that their compliance is being managed appropriately for their sector – avoiding nasty surprises or unsuccessful compliance.

For some industry sectors, failure to comply can cause momentous damage, beyond the obvious financial difficulties and time-to-market delays you might expect. For sensitive markets, like pharmaceutical or food and beverage, regulatory failure can wreak havoc on a brand’s reputation. What’s more, if the uncompliant product is subject to a recall, or the company is issued with a newsworthy penalty charge, the reputational damage can be irreparable.

PLM software is widely regarded as an effective tool to simplify product design. However, by providing a single source of truth for the entire development process, the potential of PLM surpasses this basic function. Using PLM for compliance equips manufacturers with complete data traceability, from the initial stages of design, right through to product launch. What’s more, industry-specific applications are dramatically simplifying the entire compliance process by guaranteeing businesses can meet particular regulations from the very outset.

Meeting regulatory standards is an undisputed obligation for product designers. However, as the strategic and product quality benefits of design-for-compliance become more apparent, it is likely that complying through PLM will become standard practice in the near future.

#PLM @designruleltd #PAuto #Pharma #Food @StoneJunctionPR

Endress+Hauser has produced over two million electromagnetic flowmeters since 1977. “That is more than any other manufacturer,” they claim. “This magic number stands for high-quality measuring technology and, above all, satisfied customers in all kinds of industries,” says Bernd-Josef Schäfer, Managing Director of Endress+Hauser Flowtec AG, the center of competence for flow measuring technology.

The company’s success story as a manufacturer of electromagnetic flowmeters began in the middle of the 1970s. In order to enter the water and wastewater market which was emerging at that time, Endress+Hauser purchased the company Flowtec in Bern in 1977 and moved it to a new location in Reinach (Basel-Landschaft, Switzerland). This is where Endress+Hauser started to produce flowmeters with just three employees in former military barracks.

Work was done on an on-demand basis. “Whereas today,” says Bernd-Josef Schäfer, “our production spans six sites around the globe – in Switzerland, France, the USA, China, India, and Brazil – and boasts state-of-the-art logistics. This infrastructure is what has enabled us to produce two million electromagnetic flowmeters to date in accordance with required quality standards.”

To put this into context: These two million electromagnetic flowmeters could measure a volume corresponding to four times the flow rate of the Amazon. Each production site also features precise calibration facilities which are regularly checked by national accreditation bodies and which guarantee consistently high measuring quality for each individual device.

Constant innovation guarantees customer satisfaction
The company’s success, which spans almost 40 years, is due to many factors. In particular, its inventive talent has enabled Endress+Hauser to keep offering its customers new, groundbreaking devices capable of measuring all kinds of fluids, such as water, milk, acids, alkalis, or ore slurry, with the greatest accuracy.

With clever innovations such as the precision measurement of difficult fluids (Autozero, 1981), microprocessor control (Variomag, 1984), two-wire technology (Eximag, 1987), or the operating matrix (Tecmag, 1990), Endress+Hauser has always managed to stay one step ahead of the competition.

In 1993, all of these device variants were brought together to form a single product family under the name of “Proline”. Alongside this family, however, Endress+Hauser also produces flowmeters for very particular applications – for example, filling bottles at one-second intervals.

Looking to the future with Proline
Since 1993, the Proline device family has undergone constant development to ensure that it meets the prevailing requirements in a wide range of industries. Following the second generation launched in 2000, the third and most recent Proline generation (2012) offers a multitude of unique functions and device properties.

This means that system operators will not only be able to retrieve measurement and diagnostic data via display, WLAN, web server, or fieldbus, but will also be able to monitor the process comprehensively and, if necessary, check the functioning of a flowmeter during operation.

Bernd-Josef Schäfer sees the future of Endress+Hauser optimistically: “Innovations such as these enable us to align our product portfolio consistently with the needs of every industry. We are looking ahead to our three-millionth electromagnetic flowmeter with great confidence.”

@Endress_Hauser #PAuto

ISA’s first international symposium outside of North America is adjudged a success.

From the time it was firsted mooted for Ireland in 2015 the planning for the 3rd ISA Food & Pharmaceutical Symposium was embraced with enthusiasm by the local Ireland Section. This was in Philadelphia early in 2015 and since then the ISA’s Food & Pharma Division under the able directorship of Canadian Andre Michel has ploughed forward overcoming setbacks and the not inconsiderable distances between North America and the capital of Munster. Chair of the symposium and former Ireland Section President, Dave O’Brien directed a strong committee charged with ensuring the this, the first such international symposium organised by the ISA outside of North America would be a resounding success.

And it was.

Venues were assessed, speakers recruited and the various minutiae associated with organising an international event were discussed, duties asigned and problems solved over many late night transatlantic telephone conferences. Using the experience of the ISA staff in North Carolina and the many years experience of organising table-top events and conferences in Ireland by the Ireland Section a very creditable event was staged at the Rochestown Park Hotel. With some justification the Symposium Chair could state before the event started “We have assembled a truly outstanding program this year, featuring some of the world’s most accomplished experts in serialization, process optimization, cyber security and alarm management to name a few. These experts will speak on the vital issues affecting food and drug manufacturers and distributors. We are delighted to have the opportunity to bring this event to Ireland for its first time outside of the United States!” Indeed upwards of 200 registrands attended the two day event and it was notable that the bulk of these stayed until the final sessions were completed.

ISA President Jim Keaveney (3rd from right) with some of the speakers ath the FPID Symposium

Technology and Innovation for 2020 Global DemandsTwo fluent keynote speakers, Paul McKenzie, Senior Vice President, Global Biologics Manufacturing & Technical Operations at Biogen (who addressed “Driving Change Thru Innovation & Standards”) and Dr Peter Martin, VP and Edison Master, Schneider Electric Company (Innovation and a Future Perspective on Automation and Control) may be said to have set the tone. The event was also graced with the presence of ISA Internationa President for 2016 Mr Jim Keaveney.

We will highlight a few of the sessions here!

Serialization:
The important subject of serialization which affects all level of the pharmaceutical business especially in view of deadlines in the USA and the EU. From an overview of the need and the technology to a deep dive into the user requirements, this session provided the latest information on the world requirements and helping provide the solution needed in each facility. Speakers, as in most sessions, were drawn from standard, vendor and user organisations as well as state enforcement agencies.

Track & Trace:
In the parallel Food thread of the symposium the role of track and trace technologies were examined. Product safety, output quality, variability and uniqueness of customer requirements manufacturers are facing increasing demands on the traceability of raw materials, real-time status of manufactured goods and tracking genealogy of products throughout the value chain from single line to the multiple sites of global manufacturers. The evolution of data systems and technologies being offered means greater benefits for Industry and presenters Vision ID and Crest will show these solutions and the advantage of modernization.

Both threads came together for much of the event mirroring the similarity of many of the technologies and requirements of each sector.

Digitalization:
Digitalization in industry shows what bringing the worlds of automation and digitalization together provides true and advanced paperless manufacturing with more complex devices and interconnected data systems. This is an enabler to integrated operations within industry. Using MES as a core concept to create a Digital Plant and optimized solutions with data driven services was explained. And a practicale example of a plant was discussed showing the journey to paperless manufacturing and a real pharmaceutical strategy of integrating automated and manual operations.

Eric Cosman makes a point!

Cybersecurity:
Of course this is one of the key topics in automation in this day and age. Without implementing the proper preventative measures, an industrial cyber-attack can contribute to equipment failure, production loss or regulatory violations, with possible negative impacts on the environment or public welfare. Incidents of attacks on these critical network infrastructure and control systems highlight vulnerabilities in the essential infrastructure of society, such as the smart grid, which may become more of a focus for cybercriminals in the future. As well as threats from external sources steps ought to be taken to protect control and automation systems from internal threats which can cripple a company for days or months. This session highlighted the nature of these threats, how systems and infrastructure can be protected, and methods to minimize attacks on businesses.

Automation Challenges for a Greenfield Biotech Facility:
These were outlined in this session in the pharmaceutical thread. Recent advances in biotechnology are helping prepare for society’s most pressing challenges. As a result, the biotech industry has seen extensive growth and considerable investment over the last number of years. Automation of Biotech plants has become increasingly important and is seen as a key differentiator for modern biotech facilities. Repeatable, data rich and reliable operations are an expectation in bringing products to market faster, monitor and predict performance and ensure right first time delivery. This session provided the most topical trends in automation of biotech facilities and demonstrated how current best practices make the difference and deliver greater value to businesses.

Process Optimization and Rationalization:
Meanwhile in the Food & Beverage thread incremental automation improvement keeps competitiveness strong. Corporate control system standardization leads to constant demand for increases in production and quality.

Industry 4.0 (Digital Factory: Automate to Survive):

Networking between sessions

The fourth industrial revolution is happening! This session asked how Global Industry and Ireland are positioned. What did this mean to Manufacturer’s and Industry as a whole? The use of data-driven technologies, the Internet of things (IoT) and Cyber-Physical Systems all integrate intelligently in a modern manufacturing facility. Enterprise Ireland and the IDA headlined this topic along with the ICMR (Irish Centre for Manufacturing Research) and vendors Rockwell and Siemens.

Worldwide today many of the over 60 Billion Euro spend in installed control systems are reaching the end of their useful life. However, some of these controls, operational since the 80’s and 90’s, invested significantly in developing their intellectual property and much of what was good then is still good now. Of course some aspects still need to evolve with the times. This requires funding, time and talent. For quite some time now there has been a skilled automation shortage at many companies leading organizations to outsourcing, partnerships and collaboration with SME’s to help manage the institutional knowledge of their installed control systems. With corporate leadership sensitive to return to shareholders, plant renovation approval hurdle rates are usually high when it comes to refreshing these control systems. In many manufacturing facilities, engineers and production managers have been asked to cut costs and yet still advance productivity. To solve this dilemma, many world class facilities continue to focus on driving improvements through the use of automation and information technology. Some are finding that using existing assets in conjunction with focused enhancement efforts can take advantage of both worlds. Here we were shown great examples of where innovation and such experiences are helping to create real value for automatio modernization.

Alarm management:
And of course no matter how sophisticated systems are Alarms are always require and neccessary. DCSs, SCADA systems, PLCs, or Safety Systems use alarms. Ineffective alarm management systems are contributing factors to many major process accidents and so this was an importan session to end the symposium.

The social aspect of this event was not forgotton and following a wine reception there was a evening of networking with music at the end of the first day.

Training Courses:
On the Wednesday, although the symposium itself was finished there were two formal all day training courses. These covered, Introduction to Industrial Automation Security and the ANSI/ISA-62443 Standards (IC32C – Leader Eric Cosman, OIT Concepts ), and Introduction to the Management of Alarm Systems (IC39C – Leader Nick Sands, DuP0nt). These, and other, ISA courses are regularly held in North America and the Ireland Section occasionally arranges for them in Ireland.

All in all the Ireland Section and its members may feel very proud in looking back on a very well organised and informative event which in an email from one of the attendees, “Thank you all, It was the best symposium I attended in the last 10 years!”

Three things you didn’t know about IIoT examined by Martyn Williams, Managing Director of COPA-DATA UK.

The human brain is a wonderful thing that works tirelessly from the day we are born until the day we die, only stopping on special occasions, like when presenting in front of large audiences. We’ve been studying the brain for many centuries, but we still know relatively little about the trillions of connections that make it work. Creating a road map of the brain is a bit like trying to map out the Industrial Internet of Things (IIoT). IIoT is a concept that has intrigued industry for several years now, but much like the human brain, is not yet fully understood.

To gain a better understanding of the IIoT universe, we need to look at specifics. We need to understand how hardware and software, communication protocols and the human connection come together to support a stable and flexible interaction that enhances production, control and efficiency in industrial environments.

Machines to machines
Every time you form a new memory, new connections are created in the brain, making the system even more complex than before. Similarly, IIoT relies on many-to-many applications or groups of nodes to accomplish a single task. The plural of “machine” is important when discussing IIoT because it highlights the complexity of the system.

For example, on a sandwich biscuit production line, the biscuit sandwiching machine at the heart of the line should be able to communicate with the previous elements of the process, as well as the ones that come after it. The mixing, cutting and baking machines at the very start of the production process should also be able to “speak” to the conveyers, the pile packing sandwich machine, the cream feed system, lane multiplication and packaging machines. This level of communication allows the production line to be more flexible and cater for a wider range of biscuit varieties.

Instead, the nodes act as peers in a network, each making decisions and reporting to other nodes.

Besides performing core tasks, the production system is also connected to an enterprise level that can automatically issue alarms, collect and analyse data and even make predictions or recommendations based on this analysis.

A common language
IIoT will only work if it uses a compatible language across systems and industries. To help achieve this objective, industry giants AT&T, Cisco, General Electric, IBM and Intel founded the Industrial Internet Consortium in 2014. The Consortium aims to accelerate the development and adoption of interconnected machines and intelligent analytics.

As IIoT cuts across all industry sectors, from manufacturing to energy, common standards, harmonised interfaces and languages are crucial for successful implementation of the concept. The consortium hopes to lower the entry barriers to IIoT by creating a favourable ecosystem that promotes collaboration and innovation. The next step is to facilitate interoperability and open standards, allowing machines or systems from different original equipment manufacturers (OEMs) to communicate with each other and with control systems.

The old and the new
Perhaps one of the biggest challenges when it comes to implementing IIoT on a larger scale comes from integrating legacy systems with the latest generation of smart factory equipment.

Learning new things changes the structure of the brain and similarly, in manufacturing, implementing new automation equipment usually results in changes across the entire system. The solution is to use standards-based protocol gateways to integrate legacy systems in brownfield environments. This allows organisations to free data from proprietary constraints and use it for real-time and historical data collection and analysis.

There is as much risk in sticking to a single vendor based on current install base as there is to accepting these new concepts with multiple new vendors and interoperability between intelligent devices. Their concept is something that we have experienced greatly within the energy and infrastructure sector and the concepts behind IEC61850 and interoperability.

Much like the human brain, the Industrial Internet of Things is always changing and there are still a lot of questions to be answered before we fully understand its requirements, implementation and potential. Luckily, these conversations are taking place and new ideas are put into practice every day. The next step is to figure out an easy way of practically implementing IIoT innovations in manufacturing environments across the world.

Buzzwords fly around in industry like wasps at a picnic. Industry 4.0 is one of these hugely popular concepts, particularly when it comes to manufacturing. Here Steve Hughes, managing director of REO UK, gives further insight into Industry 4.0.

The first industrial revolution saw the development of mechanisation using water and steam power. The second was the introduction of electricity in manufacturing environments, which facilitated the shift to mass production. The digital revolution happened during our lifetime, using electronics and IT to further automate manufacturing.

Industry 4.0 is the fourth in this series of industrial revolutions. Although it is still, relatively speaking, in its infancy, the idea relies on sophisticated software and machines that communicate with each other to optimise production.

In Industry 4.0, strong emphasis is placed on the role of intelligent factories. They are energy efficient organisations based on high-tech, adaptable and ergonomic production lines. Smart factories aim to integrate customers and business partners, while also being able to manufacture and assemble customised products.

Industry 4.0 is more about machines doing the work and interpreting the data, than relying on human intelligence. The human element is still central to the manufacturing process, but fulfils a control, programming and servicing role rather than a shop floor function.

At Siemens’ Amberg Plant Simatic PLCs manage the production of PLCS!

The Siemens (IW 1000/34) Electronic Works facility in Amberg (D), is a good example of the next generation of smart plants. The 108,000 square-foot high-tech facility is home to an array of smart machines that coordinate everything from the manufacturing line to the global distribution of the company’s products.

Despite the endless variables within the facility, a Gartner industry study conducted in 2010 found that the plant boasts a reliability rate of more than 99 per cent, with only 15 defects in every million finished products.

Thanks to the data processing capacity of Industry 4.0-ready devices, it is possible to generate the information, statistics and trends that allow manufacturers to make their production lean and more fuel efficient.

If you work in the food manufacturing industry, you probably know that many production lines today operate at less than 60 per cent efficiency, which means there is considerable room for improvement. Saving electricity and water are also key requirements for modern plant managers, who can achieve their eco-friendly goals by using smart plant connectivity.

The great news is that a lot of the technology associated with Industry 4.0 already exists. The not so great news is that implementing it will probably cost your company a pretty penny, especially if you aim to be an early adaptor.

What the future holds
For most automation companies, the move will be a gradual one, an evolution rather than a revolution. This is why continuity with older systems will still be essential for manufacturing in the years to come.

Industry 4.0 will ultimately represent a significant change in manufacturing and industry. In the long run, the sophisticated software implanted in factory equipment could help machines self-regulate and make more autonomous decisions. Decentralisation also means tasks currently performed by a central master computer will be taken over by system components.

In years to come, geographical and data boundaries between factories could become a thing of the past, with smart plants joining up sites located in different places around the world.

Industry 4.0 is an excellent opportunity for industries to apply their skills and technologies to gradually start the shift towards smarter factories. New technologies will also lead to more flexible, sustainable and eco-friendly production and manufacturing lines. The first step is taking the Industry 4.0 concept from the land of buzzwords, to the land of research and development.

High quality components keep vacuum cleaning plant running smoothly

The Multiclean-D-4-4-F full vacuum plant from Höckh is a true giant among washing machines. While the drum of a household washing machine can hold six kilograms at any one time, an industrial washing machine recently delivered to a German customer can take two 600 kg loads of metal parts for the automotive industry.

The Multiclean-D-4-4-F full vacuum plant from Höckh is a true giant among washing machines.

In metalworking, greases and special emulsions protect cutting tools against wear. While this is good for the machines, it leaves a residue on the metal parts and must be removed before further processing. Assembly processes or surface treatments such as galvanising or painting require clean parts. Depending on the application, aqueous cleaning solutions or solvents can be used.

Solvents are preferable to aqueous cleaners for oily mass produced parts for the automotive industry as they are quick, economical and resource-saving. A new twin-chamber perchlorethylene-based cleaning plant from Höckh Metall-Reinigungsanlagen GmbH has raised the bar with operation under full vacuum.

When integrated into the production cycle, it increases part throughput significantly. Up to ten crates filled with pressed and stamped parts pass through the system every hour in a three shift operation. State-of-the-art valve terminal technology from Festo contributes to this excellent performance.

Everything in one chamber
The capacity of the huge washing machine for metal parts is simply enormous. In addition to rapidly cleaning large volumes of metal parts in either a 65° or 98° wash with liquid or vaporous perchlorethylene, the system also dries the parts using a vacuum after they have been washed. And all of this in less than 15 minutes per crate.

Before that, the pressed parts are transported in bulk. Forklift trucks move the parts in crates measuring approx. 900 x 800 x 850 mm and with a total weight of between 500 and 600 kg. To select the right program, the system operator simply scans the bar code on the accompanying ticket. As soon as he has left the loading area, automatic feeding begins and the crate is transported to the next free process chamber. To achieve the required capacity of 10 batches per hour in a three-shift operation, the process has been divided between two chambers.

The door of the giant washing machine drum is closed by a standard cylinder.

The loading gantry then loads the rotating crate holder and a Festo standard cylinder DNG with a stroke of 180 cm closes the sliding door of the process chamber vacuum tight. When it reaches the last few centimetres, a clever toggle lever mechanism ensures it is firmly closed.

When the door reaches the last few centimetres, a clever toggle lever mechanism ensures it is firmly closed.

10 batches per hour
Depending on the parts type, this is then followed by an individual cleaning programme, which can be made up of various modules such as evacuation of the process chamber to process vacuum, pre-washing in the spray process, flood cleaning (full bath) from tank one, post washing in the spray process, flood cleaning (full bath) from tank two, vapour degreasing with solvent vapour and vacuum drying. A limit value encoder monitors the drying process so that only completely dry, solvent free parts are removed from the process chamber.

When the door reaches the last few centimetres, a clever toggle lever mechanism ensures it is firmly closed.

The cleaned parts then pass through a cooling tunnel on the unloading roller conveyor so that the crates can be packed directly for shipment. To achieve maximum flexibility, the system was designed as three separate modules.

For cleaning there are two identical, completely independent cleaning modules with process chamber, twin tank, distillation plant, pumps and filters. Because of standalone operation, one module can be switched off in the event of maintenance or low capacity utilisation and the system can continue to operate at half capacity. Both cleaning modules are connected to a central supply module, which houses the vacuum pumps as well as the activated carbon absorber for process air preparation.

The entire vacuum performance of over 1,000 m³/h can be divided into variable ratios between the two process chambers if required. This ensures a very high throughput for the size of the chamber and the complexity of the process of 10 batches per hour.

Reliable process engineering
This demanding process is kept running smoothly by a variety of Festo components. These include valve terminals type CPX/MPA with Profibus control. These valve terminals look after all of the process engineering, activate the angle seat valves and the actuators, ensure the crates are locked and control the liquid transport and the vacuum.

Thanks to ‘intelligence on the terminal’; the cleaning plant from Höckh does not require any additional multi-pin cables. The MS series service unit ensures correct and reliable compressed air preparation. The latest Festo technology also offers a condition monitoring option. Values such as maximum, peak and average consumption as well as effective and apparent power are displayed.